Captive shear bolt

ABSTRACT

A captive shear bolt assembly includes a bolt and a shear coupling. The bolt may have a head, an extension, and a shank. The shear coupling may be configured to be received by the extension. The shear coupling may be configured to receive the extension via an orifice in the shear coupling. The shear coupling may be configured to shear when an upper head of the shear coupling is driven at a threshold torque. When the shear coupling has sheared, the extension may be configured to captively secure the upper head to the bolt. The captive shear bolt assembly may be used in a tap connector for electrically connecting a main conductor to a tap conductor.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/582,532, filed Sep. 25, 2019, which is a divisional of U.S. patentapplication Ser. No. 15/890,660, filed Feb. 7, 2018 (now U.S. Pat. No.10,465,732), which claims priority to U.S. Provisional PatentApplication No. 62/468,564, filed Mar. 8, 2017, and to U.S. ProvisionalPatent Application No. 62/529,228, filed Jul. 6, 2017, each of which areincorporated herein in their entirety by reference.

BACKGROUND

Shear bolts are well known. A typical shear bolt may be configured toshear under a threshold torque. For example, a typical shear bolt mayinclude a shear section that is configured to shear when a thresholdtorque is applied at a head of the shear bolt. The shear section may belocated at a shoulder, a head, and/or the threads of the typical shearbolt. When a typical shear bolt shears, the sheared portion of the boltis separated from the securing portion of the shear bolt. The separatedportion (e.g., sheared portion) may fall to the ground below.

Electrical connector assemblies are well known. An electrical connectorassembly may be adapted to electrically and mechanically connectconductors within a transmission or distribution circuit. For example, atypical electrical connector assembly may be used to connect a mainconductor to a tap or run conductor. An electrical connector assemblyadapted to connect a transmission conductor or a tap conductor toanother conductor may be referred to as a tap connector. A tap connectormay include a C-shaped body having a curved top wall adapted to fit overa main conductor (e.g., such as a transmission conductor). Abolt-operated wedge may be carried by the bottom of the C-shaped bodyand may include an elongated recess in the top for supporting the tapconductor (e.g., such as a distribution conductor). A bolt may beoperated to positively move the wedge both in and out so that theclamping action of the connector can be tightened or loosened asdesired.

The use of shear bolts in tap connectors is well known. For example, ashear bolt may be used to tighten the clamping action of the connectorsuch that a tap conductor is captively engaged within the tap connector.However, it would be desirable if there were available shear bolts thatcould prevent the sheared section of the shear bolt from falling to theground below.

SUMMARY

As described herein, a captive shear bolt assembly may include a boltand a shear coupling. The bolt may have a head, an extension extendingfrom a top surface of the head, and a shank extending from a bottomsurface of the head. The bolt may include a first cavity and a secondcavity, for example, through an axis of rotation of the bolt. The firstcavity may extend partially into the extension. The second cavity mayextend partially into the shank (e.g., the non-threaded portion and/orthe threaded portion). The shank may be partially threaded. For example,the shank may include a shoulder, a threaded portion, and a non-threadedportion. The shoulder may extend from the bottom surface of the head tothe threaded portion. The shoulder may not have any threads. Thenon-threaded portion may be between the threaded portion and a distalend of the shank. The non-threaded portion may have a first diameterthat is less than a second diameter of the shoulder. The first diametermay be less than or equal to a minor diameter of the threads of thethreaded portion. The shank may be configured to receive a lock washeror a retaining ring. The retaining ring may be installed radially oraxially onto the shank.

The shear coupling may include an upper head, a lower head, and a shearsection. The shear coupling may define an orifice therethrough. Theshear coupling (e.g., via the orifice) may be configured to receive theextension and the head of the bolt. An upper portion of the extensionmay be configured to be deformed (e.g., partially deformed) by insertinga tool within the first cavity. The deformed upper portion may beconfigured to prevent removal of the shear coupling from the bolt (e.g.,the extension). The deformed upper portion of the extension may beconfigured to engage an upper inner surface of the upper head such thatthe upper head is captively secured to the bolt.

The shear section may be configured to shear when the upper head isdriven at a pre-determined (e.g., threshold) torque. The shear sectionmay be located between the upper head and the lower head. The shearsection may define a tapered cross section with a first diameter at alower surface of the upper head, a second diameter at an upper surfaceof the lower head, and a third diameter at a midpoint between the uppersurface and the lower surface. The first diameter and the seconddiameter may be greater than the third diameter. The third diameter maybe configured such that the shear section shears at the pre-determinedtorque. When the shear section has sheared, the extension may beconfigured to captively secure the shear coupling (e.g., the upper head)to the bolt.

As described herein, an electrical connector may be configured toelectrically connect a main conductor (e.g., such as a transmissionconductor) to a tap conductor (e.g., such as a distribution conductor).The electrical connector may be referred to as a tap connector. The tapconnector may include a captive shear bolt assembly. The tap connectormay include a body member, for example, a substantially C-shaped bodymember. The body member may have a curved top wall configured to receivea main conductor. The tap connector may include a wedge configured to bereceived by the body member. The wedge may be configured to receive adistribution connector. The tap connector may include a conductorinterface insert. The conductor interface insert may define an uppersurface configured to engage the main conductor and may define a lowersurface configured to engage the distribution connector. The conductorinterface insert may be configured to electrically connect the mainconductor and the tap conductor.

The tap connector may include one or more lock washers or retainingrings for retaining the captive shear bolt within the wedge and/or bodymember. The wedge may include a tab with an aperture. The aperture maybe configured to receive the shank of the captive shear bolt. The wedgemay include a slide with an orifice. The orifice may be configured toreceive the shank of the captive shear bolt. The captive shear bolt maybe configured to shear when the wedge is in a position such that themain conductor and the tap conductor are electrically connected.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an example captive shear bolt assembly.

FIG. 1B is a cross-section view of the example captive shear boltassembly shown in FIG. 1A.

FIGS. 1C and 1D are exploded views of the example captive shear boltassembly shown in FIG. 1A.

FIG. 2A is an example tap connector that includes a captive shear boltassembly.

FIG. 2B is an exploded view of the example tap connector shown in FIG.2A.

FIG. 3A is another example captive shear bolt assembly.

FIG. 3B is a cross-section view of the example captive shear boltassembly shown in FIG. 3A.

FIG. 3C is an exploded view of the example captive shear bolt assemblyshown in FIG. 3A.

FIG. 4A is another example tap connector that includes a captive shearbolt assembly.

FIG. 4B is an exploded view of the example tap connector shown in FIG.4A.

FIG. 5A is another example captive shear bolt assembly.

FIG. 5B is a cross-section view of the example captive shear boltassembly shown in FIG. 5A.

FIG. 5C is an exploded view of the example captive shear bolt assemblyshown in FIG. 5A.

FIG. 6A is another example tap connector that includes a captive shearbolt assembly.

FIG. 6B is an exploded view of the example tap connector shown in FIG.6A.

DETAILED DESCRIPTION

FIGS. 1A-1D depict an example captive shear bolt assembly 100. Theexample captive shear bolt assembly may include a bolt 110, a cap nut120, and a screw 130. The bolt 110 may include a head 112, a shank 114,and a stud 115. The head 112 may be hexagonal. The head 112 may define atop surface 122 and a bottom surface 123. The stud 115 may extend fromthe top surface 122. The shank 114 may extend from the bottom surface123. The shank 114 may include a shoulder 116, a threaded portion 118, anon-threaded portion 124, and a protrusion 128. The shoulder 116 may bebetween the bottom surface 123 of the head 112 and the threaded portion118. The threaded portion 118 may be between the shoulder 116 and thenon-threaded portion 124. The non-threaded portion 124 may have a firstcross-sectional area that is less than or equal to a minor diameter ofthe threaded portion 118. The protrusion 128 may define the distal end126 of the shank 114. The protrusion 128 may have a second crosssectional area that is less than the first cross sectional area of thethreaded portion 118. The protrusion 128 may be configured to accept alock washer or a retaining ring. For example, a retaining ring may beradially or axially installed onto the protrusion 128.

The bolt 110 may define a cavity 140. The cavity 140 may be located(e.g., centered) at an axis of rotation 160 of the bolt 110. The cavity140 may extend through the stud 115 and the head 112. The cavity 140 mayextend partially into the shank 114. The cavity 140 may be configured toreceive the screw 130. For example, the cavity 140 may include internalthreads 146. The internal threads 146 of the cavity 140 may begin afterthe shear section 142.

The stud 115 may be threaded. For example, the stud 115 may includeexternal threads 144. The stud 115 may define a shear section 142. Theshear section 142 may be between the top surface 122 of the head 112 andthe external threads 144. The shear section 142 may define a taperedcross section with a first diameter at the top surface 122 of the head112 and a second diameter at a start of the external threads 144. Thefirst diameter may be greater than the second diameter. The shearsection 142 may be configured to shear at or above a threshold torque.For example, the second diameter may be determined based on thethreshold torque.

The cap nut 120 may be hexagonal (e.g., a hexagonal cap nut). The capnut 120 may define an orifice 150 on the top surface 152 of the cap nut120. The orifice 150 may be configured to receive the screw 130. Forexample, the orifice may receive one or more threads 132 of the screw130 and/or a head 134 of the screw 130. The cap nut 120 may includeinternal threads that allow the cap nut 120 to be threaded onto the stud115. When the cap nut 120 is threaded onto the stud 115, the orifice 150may be aligned with the cavity 140 such that the screw 130 may beinstalled in the cavity 140 through the orifice 150.

The screw 130 may include threads 132 and a head 134. The head 134 maydefine a recessed drive hole 136. The recessed drive hole 136 may beconfigured to receive a hexagonal (e.g., such as an Allen wrench) drive.

The cap nut 120 may be threaded onto the bolt 110. For example, the capnut 120 may be threaded onto the external threads 144 of the stud 115.The screw 130 may be inserted into the cavity 140 via the orifice 150.The captive shear bolt assembly 100 may be configured to be driven atthe cap nut 120. As torque is applied to the cap nut 120, the captiveshear bolt assembly 100 may rotate as the threaded portion 118 engagescomplementary threads. When the applied torque exceeds a thresholdtorque, the shear section 142 of the stud 115 may shear such that thecap nut 120 and the stud 115 are mechanically decoupled from thethreaded portion 118 of the bolt. For example, when the shear section142 shears, the cap nut 120 may no longer drive the threaded portion 118of the bolt 110. When the shear section 142 of the stud 115 shears, thescrew 130 may captively secure the cap nut 120 and the stud 115 to thebolt 110. For example, the screw 130 may engage threads in the head 112portion of the cavity 140.

FIGS. 2A-2B depict an example tap connector 200 that includes a captiveshear bolt assembly 250. The example tap connector 200 may include abody member 210, a conductor interface insert 220, and a wedge 230. Thetap connector 200 may be configured to electrically and mechanicallyconnect a main conductor (e.g., such as a transmission conductor, notshown) to a tap conductor (e.g., such as a distribution conductor, notshown).

The body member 210 may be substantially C-shaped. For example, the bodymember 210 may have a rear wall 212, a curved top wall 214 and a curvedbottom wall 216. The curved top wall 214 may be configured to receivethe distribution connector. For example, the curved top wall 214 of thetap connector 200 may fit partially around the main conductor. Thecurved bottom wall 216 may be configured to receive the wedge 230. Therear wall 212 may be substantially flat. The rear wall 212 may define astop 218 that extends away from the rear wall 212.

The conductor interface insert 220 may be located between the mainconductor and the tap conductor. The conductor interface insert 220 maybe elongated in shape having a length substantially the same as the bodymember 210. An upper surface 224 of the conductor interface insert 220may define a first recess 222. A lower surface 226 of the conductorinterface insert 220 may define a second recess 228. The first recess222 and the second recess 228 may be similarly shaped. The first recess222 may be configured to receive (e.g., partially receive) the mainconductor. The second recess 228 may be configured to receive (e.g.,partially receive) the tap conductor. A handle 229 may extend from theconductor interface insert 220. The handle 229 may extend beyond thebody member 210. The handle 229 may be held by a pair of pliers so thatthe same can be easily moved into or out of place in the tap connector200. The handle 229 may be held by a hot stick (not shown), for example,during live work. A hot stick may be an insulated pole used when workingon energized connectors and/or conductors.

The transmission and tap conductors may be of substantially the samediameter. Accordingly, the first and second recesses 222, 228 of theconductor interface insert 220 may have substantially the sameconfiguration and/or diameter of curvature. In some applications,however, it may be desirable to connect a tap conductor of smallerdiameter with a larger diameter main conductor or a tap conductor oflarger diameter with a smaller diameter main conductor. The conductorinterface insert 220 may define recesses with different diameters ofcurvature.

The wedge 230 may include a recess 232 along an elongated upper surface234. The recess 232 may be configured to receive the distributionconnector. For example, the recess 232 may cooperate with a bottomsurface of the tap conductor. The wedge 230 may include a slide 236 thatis configured to guide the wedge 230 into the body member 210. Forexample, the slide 236 may be received within the curved bottom wall 216of the body member 210.

The tap connector may include a first tab and a second tab. The firsttab may extend (e.g., downwardly) from the wedge 230. The first tab maydefine a first aperture passing therethrough. The second tab may extend(e.g., downwardly) from the body member 210. The second tab may define asecond aperture passing therethrough. The second aperture may bethreaded. For example, the second aperture may define threads that arecomplementary to the threads of the captive shear bolt assembly 250. Thefirst tab and the second tab may be configured substantiallycomplementary to the cross-sectional shape of the curved bottom wall 216such that the first and second tabs in cooperation with the curvedbottom wall 216 guide the wedge 230 as it moves into and out of the bodymember 210.

The captive shear bolt assembly 250 (e.g., such as the example captiveshear bolt assembly shown in FIGS. 1A-1D) may include a bolt 260, a capnut 270, and a screw 280. The bolt 260 may include a head 262, a shank264, and a threaded stud 266. The head 262 may be hexagonal. Thethreaded stud 266 may extend from the head 262. The shank 264 may extendfrom the head 262, for example, in an opposite direction than thethreaded stud 266. The shank 264 may include a shoulder 267, a threadedportion 268, a non-threaded portion 274, and a protrusion 278. Theshoulder 267 may be between the head 262 and the threaded portion 268.The threaded portion 268 may be between the shoulder 267 and thenon-threaded portion 274. The non-threaded portion 274 may have a firstcross-sectional area that is less than or equal to a minor diameter ofthe threaded portion 268. The protrusion 278 may define the distal end276 of the shank 264. The protrusion 278 may have a second crosssectional area that is less than the first cross sectional area of thethreaded portion 268. The protrusion 278 may be configured to accept aretainer 290. The retainer 290 may be a lock washer or a retaining ringthat may be radially or axially installed onto the protrusion 278. Theretainer 290 may be configured to retain the captive shear bolt assembly250 within the tap connector 200.

The captive shear bolt assembly 250 may be received by the first andsecond apertures of the first and second tabs. For example, the shank264 of the captive shear bolt assembly 250 may be received by the firstand second apertures. A washer 272 may be received by the shank 264 suchthat when installed, the washer 272 is in contact with the head 262 andthe wedge 230. A second retainer (not shown) may be received by theshank 264. The second retainer may be a lock washer or a retaining ring.For example, the second retainer may be radially or axially installed onthe shank 264 after the shank 264 extends through the first tab.

When the captive shear bolt assembly 250 is rotated in a clockwisedirection, the captive shear bolt assembly is threaded into the secondaperture of the second tab and the head 262 applies a force to the firsttab such that the entire wedge 230 is moved within the body member 210.For example, the slide 236 is moved within the curved bottom wall 216 ofthe body member 210. When the wedge 230 is moved within the body member210, the upper surface 234 of the wedge 230 moves upwardly toward thecurved top wall 214. When the captive shear bolt assembly 250 is rotatedin a counter clockwise direction, the wedge 230 may move away from thebody member 210. For example, the second retainer may abut the first tabsuch that the second retainer applies a force to the first tab thatmoves the wedge 230 away from the body member 210. When the wedge 230 ismoved away from the body member 210, the upper surface 234 of the wedge230 may move downwardly away from the curved top wall 214.

The tap connector 200 may be configured such that it is assembledwithout the conductor interface insert 220 in place. The captive shearbolt assembly 250 may be in a position such that the wedge 230 issubstantially withdrawn from the body member 210. The tap connector 200may be suspended from a main conductor by resting the curved top wall214 of the body member 210 around the main conductor. A tap conductormay be laid across the upper surface 234 of the wedge 230. The conductorinterface insert 220 may be positioned between the transmission and tapconductors, for example, outside of the body member 210. The conductorinterface insert 220 may be moved toward the interior of the body member210, for example, using the conductors as a guide. The conductorinterface insert 220 may be moved until a leading surface 221 of theconductor interface insert 220 contacts the stop 218.

With the conductor interface insert 220 in place, the captive shear boltassembly 250 may be rotated such that the wedge 230 is moved towardinterior of the body member 210. The captive shear bolt assembly 250 maybe rotated via the cap nut 270. As the wedge 230 is moved into theinterior of the body member 210, the recess 232 is moved into contactwith the tap conductor which in turn is forced against the second recess228 on the lower surface 226 of the conductor interface insert 220. Thefirst recess 222 on the upper surface 224 of the conductor interfaceinsert 220 may be forced into contact the main conductor which in turnis forced into contact with the curved top wall 214 of the body member210. The captive shear bolt assembly 250 may be configured to shear at athreshold torque. For example, the threshold torque may be determinedsuch that it corresponds to the wedge 230 being in its proper positionand sufficient pressure being placed on the conductors so as to providea proper connection. The captive shear bolt assembly 250 may shear atthe threaded stud 266. The screw 280 may be configured to retain the capnut 270 and the threaded stud 266 to the bolt 260 when the threaded stud266 shears.

FIGS. 3A-3C depict another example captive shear bolt assembly 300. Theexample captive shear bolt assembly 300 may include a bolt 310, a shearcoupling 315, and a screw 330. The bolt 310 may include a head 312 and ashank 314. The head 312 may be hexagonal. The head 312 may define a topsurface 322 and a bottom surface 323. The shank 314 may extend from thebottom surface 323. The shank 314 may include a shoulder 316, a threadedportion 318, a non-threaded portion 324, and a protrusion 328. Theshoulder 316 may be between the bottom surface 323 of the head 312 andthe threaded portion 318. The threaded portion 318 may be between theshoulder 316 and the non-threaded portion 324. The non-threaded portion324 may have a first cross-sectional area that is less than or equal toa minor diameter of the threaded portion 318. The protrusion 328 maydefine the distal end 326 of the shank 314. The protrusion 328 may havea second cross sectional area that is less than the first crosssectional area of the threaded portion 318. The protrusion 328 may betapered from the shank 314 to the distal end 326. The protrusion 328 maybe configured to accept a retainer (e.g., such as a retaining ringand/or a lock washer).

The shear coupling 315 may define an upper head 320, a lower head 325,and a shear section 342. The upper head 320 and/or the lower head 325may be hexagonal-shaped. For example, the upper head 320 may be a firsthexagonal nut and the lower head 325 may be a second hexagonal nut. Theupper head 320 and the lower head 325 may be connected by the shearsection 342. The upper head 320 may be configured to receive an externaltorque. The shear section 342 may define a tapered cross section with afirst diameter at the upper head 320 and a second diameter at the lowerhead 325. The first diameter may be greater than the second diameter.The shear section 342 may be configured to shear at or above a thresholdtorque. For example, one or more of the second diameter, the material,and/or the thickness of the shear section 342 may be determined based onthe threshold torque.

The shear coupling 315 may define an orifice 350. The orifice 350 mayextend through the upper head 320, the shear section 342, and the lowerhead 325. For example, the orifice 350 may start at a top surface 352 ofthe upper head 320 and may terminate at a bottom surface 354 of thelower head 325. The orifice 350 may be configured to receive the screw330. For example, the orifice may receive one or more threads 332 of thescrew 330 and/or a head 334 of the screw 330.

The bolt 310 may define a cavity 340. The cavity 340 may be located(e.g., centered) at an axis of rotation 360 of the bolt 310. The cavity340 may extend through the head 312. The cavity 340 may extend partiallyinto the shank 314. The cavity 340 may define a top portion 344 and abottom portion 348. The top portion 344 may be hexagon-shaped. Forexample, the top portion 344 may be configured to receive the lower head325 of the shear coupling 315. The top portion 344 may be configuredsuch that a torque applied to the shear coupling 315 (e.g., the upperhead 320 of the shear coupling 315) is transferred to the bolt 310. Thecavity 340 may be configured to receive the screw 330. For example, thecavity 340 may include internal threads 346 (e.g., female threads). Theinternal threads 346 of the cavity 340 may begin after the shear section342. When the shear coupling 315 is inserted into the head 312, theorifice 350 may be aligned with the cavity 340 such that the screw 330may be installed in the cavity 340 through the orifice 350.

The screw 330 may include threads 332 and a head 334. The head 334 maydefine a drive recess 336. The head 334 may be a Phillips (e.g.,crosshead) screw head. For example, the drive recess 336 may beconfigured to receive a Phillips-head drive. Although, the drive recess336, as shown, may be configured to receive a Phillips-head drive, thehead 334 may be configured to receive another type of drive. Forexample, the head 334 may be configured to receive a flat head drive, aTorx drive, a square drive, a hex socket drive, etc.

The shear coupling 315 may be inserted into the cavity 340. For example,the lower head 325 of the shear coupling 315 may be inserted into thetop portion 344 of the cavity 340. The screw 330 may be inserted intothe cavity 340 via the orifice 350 in the shear coupling 315. Thethreads 332 of the screw 330 may engage internal threads 346 in thebottom portion 348 of the cavity 340. The captive shear bolt assembly300 may be configured to be driven at the shear coupling 315, forexample, the upper head 320 of the shear coupling 315. As torque isapplied to the upper head 320, the captive shear bolt assembly 300 mayrotate as the threaded portion 318 engages complementary threads. Whenthe applied torque exceeds a threshold torque, the shear section 342 ofthe shear coupling 315 may shear such that the upper head 320 ismechanically decoupled from the threaded portion 318 of the bolt 310.For example, when the shear section 342 shears, the upper head 320 mayno longer drive the threaded portion 318 of the bolt 310. When the shearsection 342 of the shear coupling 315 shears, the screw 330 maycaptively secure the upper head 320 to the bolt 310. For example, thescrew 330 may engage the internal threads 346 in the bottom portion 348of the cavity 340 such that the shear coupling 315 remains coupled tothe bolt 310 when the shear section 342 has sheared.

The captive shear bold assembly 300 may be configured to be reused. Forexample, when the shear section 342 has sheared, the screw 330 may beremoved such that the shear coupling 315 may be removed. A replacementshear coupling may be installed such that the captive shear boltassembly 300 can be reused.

FIGS. 4A-4B depict an example tap connector 400 that includes a captiveshear bolt assembly 450 (e.g., such as the captive shear bolt assembly300 shown in FIGS. 3A-3C). The example tap connector 400 may include abody member 410, a conductor interface insert (not shown), and a wedge430. The tap connector 400 may be configured to electrically andmechanically connect a main conductor (not shown) to a tap conductor(not shown).

The body member 410 may be substantially C-shaped. For example, the bodymember 410 may have a rear wall 412, a curved top wall 414 and a curvedbottom wall 416. The curved top wall 414 may be configured to receivethe distribution connector. For example, the curved top wall 414 of thetap connector 400 may fit partially around the main conductor. Thecurved bottom wall 416 may be configured to receive the wedge 430. Therear wall 412 may be substantially flat. The rear wall 412 may define astop 418 that extends away from the rear wall 412.

The conductor interface insert may be located between the main conductorand the tap conductor. The conductor interface insert may be elongatedin shape having a length substantially the same as the body member 410.An upper surface of the conductor interface insert may define a firstrecess. A lower surface of the conductor interface insert may define asecond recess. The first recess and the second recess may be similarlyshaped. The first recess may be configured to receive (e.g., partiallyreceive) the main conductor. The second recess may be configured toreceive (e.g., partially receive) the tap conductor. A handle may extendfrom the conductor interface insert. The handle may extend beyond thebody member. The handle may be held by a pair of pliers so that the samecan be easily moved into or out of place in the tap connector 400. Thehandle may be held by a hot stick (not shown), for example, during livework. A hot stick may be an insulated pole used when working onenergized connectors and/or conductors.

The transmission and tap conductors may be of substantially the samediameter. Accordingly, the first and second recesses of the conductorinterface insert may have substantially the same configuration and/ordiameter of curvature. In some applications, however, it may bedesirable to connect a tap conductor of smaller diameter with a largerdiameter main conductor or a tap conductor of larger diameter with asmaller diameter main conductor. The conductor interface insert maydefine recesses with different diameters of curvature.

The wedge 430 may include a recess 432 along an elongated upper surface434. The recess 432 may be configured to receive the distributionconnector. For example, the recess 432 may cooperate with a bottomsurface of the tap conductor. The wedge 430 may include a slide 436 thatis configured to guide the wedge 430 into the body member 410. Forexample, the slide 436 may be received within the curved bottom wall 416of the body member 410. The slide 436 may be configured substantiallycomplementary to the cross-sectional shape of the curved bottom wall 416such that the slide 436, in cooperation with the curved bottom wall 416,is configured to guide the wedge 430 as it moves into and out of thebody member 410. The slide 436 may define an orifice 438 that may beconfigured to receive the captive shear bolt assembly 450.

The wedge may define a tab 420. The tab 420 may extend (e.g.,downwardly) from the wedge 430. The tab 420 may define an aperture 422passing therethrough. The tab 420 may be configured substantiallycomplementary to the cross-sectional shape of the curved bottom wall 416such that a rear wall 424 of the tab 420 is configured to engage (e.g.,align with) a front wall 417 of the body member 410.

The captive shear bolt assembly 450 (e.g., such as the example captiveshear bolt assembly 300 shown in FIGS. 3A-3C) may include a bolt 460, ashear coupling 470, and a screw 480. The bolt 460 may include a head462, a shank 464, and a threaded stud 466. The head 462 may behexagonal. The threaded stud 466 may extend from the head 462. The shank464 may include a shoulder 467, a threaded portion 468, a non-threadedportion 474, and a protrusion 478. The shoulder 467 may be between thehead 462 and the threaded portion 468. The threaded portion 468 may bebetween the shoulder 467 and the non-threaded portion 474. Thenon-threaded portion 474 may have a first cross-sectional area that isless than or equal to a minor diameter of the threaded portion 468. Theprotrusion 478 may define the distal end 476 of the shank 464. Theprotrusion 478 may have a second cross sectional area that is less thanthe first cross sectional area of the threaded portion 468. Theprotrusion 478 may be configured to accept a retainer 490. The retainer490 may be a lock washer or a retaining ring. The retainer 490 may beconfigured to retain the captive shear bolt assembly 450 within the tapconnector 400.

The captive shear bolt assembly 450 may be received by the aperture 422of the tab 420 and the orifice 438 of the slide 436. For example, theshank 464 of the captive shear bolt assembly 450 may be received by theaperture 422 and the orifice 438. A washer 472 may be received by theshank 464 such that when installed, the washer 472 is in contact withthe head 462 and the wedge 430. A second retainer (not shown) may bereceived by the shank 464. The second retainer may be a lock washer or aretaining ring. For example, the second retainer may be installed on theshank 464 after the shank 464 extends through the tab 420.

When the captive shear bolt assembly 450 is rotated in a clockwisedirection, the captive shear bolt assembly 450 is threaded into theorifice 438 of the slide 436 and the head 462 applies a force to the tab420 such that the entire wedge 430 is moved within the body member 410.For example, the slide 436 is moved within the curved bottom wall 416 ofthe body member 410. When the wedge 430 is moved within the body member410, the upper surface 434 of the wedge 430 moves upwardly toward thecurved top wall 414. When the captive shear bolt assembly 450 is rotatedin a counter clockwise direction, the wedge 430 may move away from thebody member 410. For example, the second retainer may abut the tab 420such that the second retainer applies a force to the tab 420 that movesthe wedge 430 away from the body member 410. When the wedge 430 is movedaway from the body member 410, the upper surface 434 of the wedge 430may move downwardly away from the curved top wall 414.

The tap connector 400 may be configured such that it is assembledwithout the conductor interface insert in place. The captive shear boltassembly 450 may be in a position such that the wedge 430 issubstantially withdrawn from the body member 410. The tap connector 400may be suspended from a main conductor by resting the curved top wall414 of the body member 410 around the main conductor. A tap conductormay be laid across the upper surface 434 of the wedge 430. The conductorinterface insert may be positioned between the transmission and tapconductors, for example, outside of the body member 410. The conductorinterface insert may be moved toward the interior of the body member410, for example, using the conductors as a guide. The conductorinterface insert may be moved until a leading surface of the conductorinterface insert contacts the stop 418.

With the conductor interface insert in place, the captive shear boltassembly 450 may be rotated such that the wedge 430 is moved towardinterior of the body member 410. The captive shear bolt assembly 450 maybe rotated via the upper head 475. As the wedge 430 is moved into theinterior of the body member 410, the recess 432 is moved into contactwith the tap conductor which in turn is forced against a second recesson the lower surface of the conductor interface insert. A first recesson the upper surface of the conductor interface insert may be forcedinto contact the main conductor which in turn is forced into contactwith the curved top wall 414 of the body member 410. The captive shearbolt assembly 450 may be configured to shear at a threshold torque. Forexample, the threshold torque may be determined such that it correspondsto the wedge 430 being in its proper position and sufficient pressurebeing placed on the conductors to provide a proper connection. Thecaptive shear bolt assembly 450 may shear at the shear coupling 470. Thescrew 480 may be configured to retain the upper head 475 of the shearcoupling 470 to the bolt 460 when the shear section of the shearcoupling 470 has sheared.

FIGS. 5A-5C depict another example captive shear bolt assembly 500. Theexample captive shear bolt assembly 500 may include a bolt 510 and ashear coupling 515. The bolt 510 may include a head 512, an extension513, and a shank 514. The head 512 may be hexagonal, for example. Thehead 512 may define a top surface 522 and a bottom surface 523. Theextension 513 may be cylindrically-shaped, as shown. The top surface 522may be cylindrical, hexagonal, or some other shape. The extension 513may define a cavity 508. The shank 514 may extend from the bottomsurface 523. The shank 514 may include a shoulder 516, a threadedportion 518, and a non-threaded portion 524. The shoulder 516 may bebetween the bottom surface 523 of the head 512 and the threaded portion518. The shank 514 may define a groove 517 between the shoulder 516 andthe threaded portion 518. The groove 517 may be configured such that thebolt 510 is retained within a tap connector, as described herein. Forexample, the groove 517 may be configured to receive a retaining ring(not shown). The threaded portion 518 may be located between theshoulder 516 and the non-threaded portion 524. The non-threaded portion524 may have a cross-sectional area that is less than or equal to aminor diameter of the threaded portion 518. The non-threaded portion 524may be configured to receive a fastener. For example, the shank 514 maydefine a cavity 521. The cavity 521 may extend a distance L1 from adistal end 526 of the non-threaded portion 524 into the shank 514 andmay include internal threads 519. The cavity 521 and the internalthreads 519 may begin at a distal end 526 of the non-threaded portion524. The cavity 521 and/or the internal threads 519 may extend into thenon-threaded portion 524 and the threaded portion 518 of the shank 514.

The shear coupling 515 may define an upper head 520, a lower head 525,and a shear section 542. The upper head 520 and/or the lower head 525may be hexagonal-shaped. For example, the upper head 520 may be a firsthexagonal nut and the lower head 525 may be a second hexagonal nut. Theupper head 520 and the lower head 525 may be connected by the shearsection 542. The upper head 520 may be configured to receive an externaltorque. The shear coupling may be configured to transfer the externaltorque to the bolt 510 such that the bolt 510 rotates around itsrotational axis when the external torque is applied to the upper head520. The shear section 542 may define a tapered cross section with afirst diameter at the upper head 520, a second diameter at the lowerhead 525, and a third diameter at a midpoint between the upper head 520and the lower head 525. The first diameter and the second diameter maybe equal. The shear section 542 may be configured to shear at or above athreshold torque. For example, one or more of the third diameter, thematerial, and/or the thickness of the shear section 542 may bedetermined and/or configured based on the threshold torque.

The shear coupling 515 may be configured to receive the extension 513and the head 512. For example, the shear coupling 515 may define anorifice 509. The orifice 509 may extend through the upper head 520, theshear section 542, and the lower head 525. For example, the orifice 509may start at a top surface 552 of the upper head 520 and may terminateat a bottom surface 554 of the lower head 525. The orifice 509 may beconfigured to receive the head 512. For example, the orifice 509 may behexagonal-shaped within the lower head 525 such that the head 512 isreceived within the orifice 509. The lower head 525 may transfer anexternal torque to the head 512 of the bolt 510. The orifice 509 mayhave different shapes and or sizes within the shear coupling 515. Withinthe upper head 520, the orifice 509 may be shaped similar to theextension 513 such that the extension 513 is received within the orifice509. For example, the orifice 509 may be cylindrical within the upperhead 520.

The shear coupling 515 and the extension 513 may be configured such thatthe shear coupling 515 can be attached to the bolt 510 using a tool. Forexample, the extension 513 may extend above an upper inner surface 541of the upper head 520. The upper inner surface 541 may be a shoulderdefined within the orifice 509. A tool (e.g., a punch) may be used todeform an upper portion of the extension 513 such that the upper portion507 extends onto (e.g., partially onto) the upper inner surface 541 ofthe upper head 520. For example, the tool may be forcibly inserted intothe cavity 508. The tool may be tapered such that the further the toolis inserted within the cavity 508, the greater the upper portion 507 isdeformed. The deformed upper portion 507 of the extension 513 may beconfigured to retain the shear coupling 515 to the bolt 510. Forexample, the deformed upper portion 507 of the extension 513 may beconfigured to prevent the shear coupling 515 from being removed from thebolt 510.

The captive shear bolt assembly 500 may be configured to be driven atthe shear coupling 515, for example, the upper head 520 of the shearcoupling 515. As torque is applied to the upper head 520, the captiveshear bolt assembly 500 may rotate as the threaded portion 518 engagescomplementary threads. When the applied torque exceeds a thresholdtorque, the shear section 542 of the shear coupling 515 may shear suchthat the upper head 520 is mechanically decoupled from the threadedportion 518 of the bolt 510. For example, when the shear section 542shears, the upper head 520 may no longer drive the threaded portion 518of the bolt 510. When the shear section 542 of the shear coupling 515shears, the deformed upper portion 507 of the extension 513 maycaptively secure the upper head 520 to the bolt 510. For example, thedeformed upper portion 507 of the extension 513 may be configured suchthat the shear coupling 515 remains coupled to the bolt 510 when theshear section 542 has sheared.

FIGS. 6A-6B depict an example tap connector 600 that includes a captiveshear bolt assembly 650 (e.g., such as the captive shear bolt assembly500 shown in FIGS. 5A-5C). The example tap connector 600 may include abody member 610, a conductor interface insert (not shown), and a wedge630. The tap connector 600 may be configured to electrically andmechanically connect a main conductor (not shown) to a tap conductor(not shown).

The body member 610 may be substantially C-shaped. For example, the bodymember 610 may have a rear wall 612, a curved top wall 614 and a curvedbottom wall 616. The curved top wall 614 may be configured to receivethe distribution connector. For example, the curved top wall 614 of thetap connector 600 may fit partially around the main conductor. Thecurved bottom wall 616 may be configured to receive the wedge 630. Therear wall 612 may be substantially flat. The rear wall 612 may define astop 618 that extends (e.g., substantially perpendicular) from the rearwall 612. The stop 618 may be configured to engage the conductorinterface insert such that the conductor interface insert is preventedfrom extending beyond the tap connector 600.

The conductor interface insert may be located between the main conductorand the tap conductor. The conductor interface insert may be elongatedin shape having a length substantially the same as the body member 610.An upper surface of the conductor interface insert may define a firstrecess. A lower surface of the conductor interface insert may define asecond recess. The first recess and the second recess may be similarlyshaped. The first recess may be configured to receive (e.g., partiallyreceive) the main conductor. The second recess may be configured toreceive (e.g., partially receive) the tap conductor. A handle may extendfrom the conductor interface insert. The handle may extend beyond thebody member. The handle may be held by a pair of pliers so that the samecan be easily moved into or out of place in the tap connector 600. Thehandle may be held by a hot stick (not shown), for example, during livework. A hot stick may be an insulated pole used when working onenergized connectors and/or conductors.

The transmission and tap conductors may be of substantially the samediameter. Accordingly, the first and second recesses of the conductorinterface insert may have substantially the same configuration and/ordiameter of curvature. In some applications, however, it may bedesirable to connect a tap conductor of smaller diameter with a largerdiameter main conductor or a tap conductor of larger diameter with asmaller diameter main conductor. The conductor interface insert maydefine recesses with different diameters of curvature.

The wedge 630 may include a recess along an elongated upper surface 634.The recess may be configured to receive the distribution connector. Forexample, the recess may cooperate with a bottom surface of the tapconductor. The wedge 630 may include a slide 636 that is configured toguide the wedge 630 into the body member 610. For example, the slide 636may be received within the curved bottom wall 616 of the body member610. The slide 636 may be configured substantially complementary to thecross-sectional shape of the curved bottom wall 616 such that the slide636, in cooperation with the curved bottom wall 616, is configured toguide the wedge 630 as it moves into and out of the body member 610. Theslide 636 may define an orifice that may be configured to receive thecaptive shear bolt assembly 650.

The wedge may define a tab 620. The tab 620 may extend (e.g.,downwardly) from the wedge 630. The tab 620 may define an aperturepassing therethrough. The tab 620 may be configured substantiallycomplementary to the cross-sectional shape of the curved bottom wall 616such that a rear wall of the tab 620 is configured to engage (e.g.,align with) a front wall of the body member 610.

The captive shear bolt assembly 650 (e.g., such as the example captiveshear bolt assembly 500 shown in FIGS. 5A-5C) may include a bolt 660, ashear coupling 670, and a fastener 680. The shear coupling 670 maydefine an upper head 675, a shear section 678, and a lower head 677. Thebolt 660 may include a head 662, a shank 664, and an extension 663. Thehead 662 may be hexagonal. The extension 663 may extend from the head662. The shank 664 may include a shoulder, a threaded portion 668, and anon-threaded portion 674. The shoulder may be between the head 662 andthe threaded portion 668. The threaded portion 668 may be between theshoulder and the non-threaded portion 674. The non-threaded portion 674may have a cross-sectional area that is less than or equal to a minordiameter of the threaded portion 668. The non-threaded portion 674 maydefine the distal end 676 of the shank 664. The non-threaded portion 674may be configured to accept a fastener 680. The fastener 680 may definea head 682 and a threaded section 685. The head 682 may be a countersunkhead, a round head, a pan head, a hex head, a washer hex head, a caphead, a button head, and/or the like. For example, the non-threadedportion 674 may define a cavity that includes internal threads 684. Theinternal threads 684 may be configured to receive the threaded section685 of the fastener 680. The fastener 680 may be configured to retainthe captive shear bolt assembly 650 within the tap connector 600. Thefastener 680 may be a screw, a bolt, or some other type of anchoringfastener.

The captive shear bolt assembly 650 may be received by the aperture ofthe tab 620 and the orifice of the slide 636. For example, the shank 664of the captive shear bolt assembly 650 may be received by the apertureand the orifice. A washer 672 may be received by the shank 664 such thatwhen installed, the washer 672 is in contact with the head 662 and thewedge 630. The head 682 of the fastener 680 may be configured to preventthe captive shear bolt assembly 650 from being removed from the wedge630. For example, the head 682 of the fastener 680 may be larger thanthe aperture through the slide 636 such that the captive shear boltassembly 650 is retained within the wedge 630.

When the captive shear bolt assembly 650 is rotated in a clockwisedirection, the captive shear bolt assembly 650 is threaded into theorifice of the slide 636 and the head 662 applies a force to the tab 620such that the entire wedge 630 is moved within the body member 610. Forexample, the slide 636 is moved within the curved bottom wall 616 of thebody member 610. When the wedge 630 is moved within the body member 610,the upper surface 634 of the wedge 630 moves upwardly toward the curvedtop wall 614. When the captive shear bolt assembly 650 is rotated in acounter clockwise direction, the wedge 630 may move away from the bodymember 610. When the wedge 630 is moved away from the body member 610,the upper surface 634 of the wedge 630 may move downwardly away from thecurved top wall 614.

The tap connector 600 may be configured such that it is assembledwithout the conductor interface insert in place. The captive shear boltassembly 650 may be in a position such that the wedge 630 issubstantially withdrawn from the body member 610. The tap connector 600may be suspended from a main conductor by resting the curved top wall614 of the body member 610 around the main conductor. A tap conductormay be laid across the upper surface 634 of the wedge 630. The conductorinterface insert may be positioned between the transmission and tapconductors, for example, outside of the body member 610. The conductorinterface insert may be moved toward the interior of the body member610, for example, using the conductors as a guide. The conductorinterface insert may be moved until a leading surface of the conductorinterface insert contacts the stop 618.

With the conductor interface insert in place, the captive shear boltassembly 650 may be rotated such that the wedge 430 is moved towardinterior of the body member 410. For example, the captive shear boltassembly 650 may be rotatably driven by an applied external torque. Thecaptive shear bolt assembly 650 may be rotated via the upper head 675.As the wedge 630 is moved into the interior of the body member 610, therecess 632 is moved into contact with the tap conductor which in turn isforced against a second recess on the lower surface of the conductorinterface insert. A first recess on the upper surface of the conductorinterface insert may be forced into contact the main conductor which inturn is forced into contact with the curved top wall 614 of the bodymember 610. The captive shear bolt assembly 650 may be configured toshear at a threshold torque. For example, the threshold torque may bedetermined such that it corresponds to the wedge 630 being in its properposition and sufficient pressure being placed on the conductors toprovide a proper connection. The captive shear bolt assembly 650 mayshear at the shear coupling 670. The extension 663 may be configured toretain the upper head 675 of the shear coupling 670 to the bolt 660 whenthe shear section 678 of the shear coupling 670 has sheared.

1. A captive shear bolt assembly, comprising: a bolt comprising: a head;a shank extending from a bottom surface of the head; and a cavityextending into the head from a top surface of the head; a nut definingan orifice therethrough; a fastener that extends through the orifice andinto the cavity; and a shear section that is configured to shear whenthe nut is driven at a threshold torque, and wherein when the shearsection has sheared, a sheared section of the captive shear boltassembly is mechanically decoupled from the bolt and the fastenercaptively secures the sheared section of the captive shear bolt assemblyto the bolt.
 2. The captive shear bolt assembly of claim 1, wherein thehead is hexagonal.
 3. The captive shear bolt assembly of claim 1,wherein the bolt further comprises a threaded stud extending from thetop surface of the head, the cavity extending through the threaded stud.4. The captive shear bolt assembly of claim 3, wherein the nut is a capnut that is received by the threaded stud.
 5. The captive shear boltassembly of claim 4, wherein the threaded stud comprises the shearsection.
 6. The captive shear bolt assembly of claim 5, wherein thesheared section of the captive shear bolt assembly comprises the cap nutand a portion of the threaded stud.
 7. The captive shear bolt assemblyof claim 6, wherein the cap nut is secured to the portion of thethreaded stud, and wherein the portion of the threaded stud is securedto the fastener.
 8. The captive shear bolt assembly of claim 1, whereina distal portion of the fastener is configured to be secured within thehead.
 9. The captive shear bolt assembly of claim 1, wherein thefastener comprises a fastener head that is configured to abut an uppersurface of the nut.
 10. The captive shear bolt assembly of claim 1,wherein the fastener is a screw, and wherein the screw is secured to thebolt via threads within a head portion of the cavity.
 11. The captiveshear bolt assembly of claim 10, wherein the screw defines a screw headwith a recessed drive hole, and wherein the orifice is configured toreceive at least a portion of the screw head.
 12. The captive shear boltassembly of claim 1, wherein the shear section is tapered such that theshear section has a first diameter at a top surface of the head and asecond diameter distal from the top surface of the head.
 13. The captiveshear bolt assembly of claim 12, wherein the first diameter is greaterthan the second diameter.
 14. An electrical connector adapted toelectrically connect a main conductor to a tap conductor, comprising: abody member with a curved top wall configured to receive the mainconductor; a wedge configured to be received by the body member, whereinthe wedge is configured to receive the tap conductor; and a captiveshear bolt assembly configured to be rotated to drive the wedge into thebody member to enable an electrical connection between the mainconductor and the tap conductor, the captive shear bolt assembly,comprising: a bolt comprising: a head; a shank extending from a bottomsurface of the head; and a cavity extending into the head from a topsurface of the head; a nut defining an orifice therethrough; and afastener that extends through the orifice and the cavity; and a shearsection that is configured to shear when the nut is driven at athreshold torque, and wherein when the shear section has sheared, asheared section of the captive shear bolt assembly is mechanicallydecoupled from the bolt and the fastener captively secures the shearedsection of the captive shear bolt assembly to the bolt.
 15. Theelectrical connector of claim 14, further comprising a conductorinterface insert having an upper surface configured to engage the mainconductor and a lower surface configured to engage the tap conductor,wherein the conductor interface insert is configured to electricallyconnect the main conductor and the tap conductor.
 16. The electricalconnector of claim 14, further comprising one or more lock washers orretaining rings for retaining the captive shear bolt assembly within thewedge and the body member.
 17. The electrical connector of claim 14,wherein the wedge includes a tab with a first orifice configured toreceive the shank of the captive shear bolt assembly.
 18. The electricalconnector of claim 17, wherein the body member is substantially C-shapedand includes a second orifice configured to receive the shank of thecaptive shear bolt assembly, and wherein the second orifice is threadedsuch that the captive shear bolt assembly is configured to move thewedge into the body member.
 19. The electrical connector of claim 14,wherein the bolt further comprises a threaded stud extending from thetop surface of the head, the cavity extending through the threaded stud,and wherein the nut is a cap nut that is received by the threaded stud.20. The electrical connector of claim 19, wherein the threaded studcomprises the shear section, and wherein the sheared section of thecaptive shear bolt assembly comprises the cap nut and a portion of thethreaded stud.